Device and process for processing organic waste

ABSTRACT

Organic matter is converted into a composition or outcome after it is deemed to be waste but before it is finally disposed of or used, for example as compost. One outcome is a solid of substantially fixed shape made of the pieces of organic matter, optionally bound together with a binder. The outcome is dry enough to substantially reduce microbial growth and related odors. The outcome is more convenient to handle and less offensive than raw organic waste and so encourages users to divert organic waste from other garbage and to participate in composting or other programs. The outcome can also be kept in the home or garage for extended periods of time without creating intolerable odors and so the user may take garbage to the curb less often than once a week. Processes for making outcomes involve reducing raw organic waste to pieces, drying the raw organic waste and, optionally mixing the pieces with a binder or water, forming the mixture into a shape and drying the formed mixture into a solid. Apparatuses for performing the processes may include a portable receiving module that interacts with a processing module. The outcomes decompose when exposed to the weather and may be used privately, for example as compost, or exchanged for consideration to an organization.

[0001] This is a non-provisional of U.S. provisional application No.60/410,327 filed Sep. 13, 2002. The entirety of that document isincorporated herein by this reference to it.

FIELD OF THE INVENTION

[0002] This invention relates to devices and processes for processingorganic waste, to compositions of matter or outcomes produced by suchdevices and processes, and to the use of such outcomes. The inventionmay be used, for example, to manage household or commercial organicwaste.

BACKGROUND OF THE INVENTION

[0003] Managing organic waste (alternately called garbage, refuse, trashetc.) is an important issue for households, industries andmunicipalities. Various methods or devices are in common use today todivert organic waste from landfills, but fail to provide fullysatisfactory solutions. The most prevalent diversion methods or devicesinclude under-sink waste disposers, garbage compacters, home composting,and municipal collection and composting. These methods or devices willbe described below.

[0004] Under-sink waste disposers are mounted below the basket of aconventional sink. Disposers are located in line between the sink basketand the sink drain line and provide means for chopping garbage intoparticles which can be washed down the drain line. A user insertsgarbage through the sink basket, turns on the tap to provide a stream ofwater sufficient to wash down the garbage, and turns on the choppingmeans. Disposers are attractive to consumers because they provide animmediate and permanent means to remove garbage from the sink area. Butwhile disposers are convenient for the user, they harm the environment.In particular, they use excessive amounts of water as required toentrain the garbage in a flow of liquid down the drain. And although thegarbage is removed from the kitchen, it is merely transplanted towhatever sewage system services the house. The transplanted garbage is aburden on the sewage system and on the environment since all sewagetreatment systems produce some form of discharge roughly in proportionto the amount of waste that they treat. Further, the potential value ofthe organic waste is lost. For these reasons, under-sink disposers havebeen banned in some jurisdictions. Under sink disposers are also notattractive to consumers that are environmentally conscious, consumersthat pay for utilities based on the amount of water they use or sewagethey produce, or consumers that use septic tanks or other private sewagetreatment devices.

[0005] Garbage compacters basically crush all garbage put into them, andplace the crushed garbage into a strong plastic bag. The volume of thegarbage is reduced, but the total mass of garbage remains unchanged. Theuser gets some benefit from having a smaller volume of garbage to storeor handle, but the weight and smell of the garbage remain and there arevirtually no benefits to the municipality since the compacted garbage ismixed with general garbage that the municipality would crush at somepoint in any event. The potential value of the organic waste is againlost.

[0006] Because of the problems with trash disposers and compacters,environmentally conscious consumers and municipalities have promotedhome composting. Home composting diverts some organic waste fromlandfills or waste treatment facilities and produces a potentiallyuseful product from it. But consumers have only been partially receptiveto home composting because it is essentially inconvenient. In homecomposting, homeowners maintain a composting bin or other receptacle intheir own yard. The occupants of the household typically collectselected organic waste in a pail and empty the pail into the compostingbin daily. Over time, the selected organic waste will turn into compostthat can be used at the household, for example, as fertilizer forgardens. The garbage remains in the home until emptied to the compostbin, and must be taken to the compost bin periodically. Taking waste tothe compost bin is often a nuisance since the compost bin is outdoorsand, for aesthetic reasons, usually located as far from the house aspossible. The compost bin also takes up space in the yard. For thesereasons, a large portion of the population simply will not practice homecomposting and a large portion of those that do will only practice itsporadically. On a municipal level, the major problem with homecomposting is that it only works well if the user has a sizable yard.Businesses and people living in apartments and condominiums, or eventownhouses with small yards, have no place for a composting bin and nouse for the volume of compost they would create. Other problems relateto the slow speed of home composting and concerns for attracting pests.These problems generally prevent meat, dairy products and other organicsfrom being home composted.

[0007] Municipal collection and composting has been proposed as a meansto improve on home composting. In a typical application, a municipalityprovides its residents with a special container for organic waste. Thehomeowners collect organic waste in the special container over thecourse of a week, and then place the container at the curb for pick up.The municipality collects the organic waste and can process it atdedicated composting sites. A municipal composting site typically breaksdown the waste faster than a home composting bin and may generate asteady supply of compost in sufficient volume to support a compost salesunit. A municipal site may also be able to extract usable biomass orgases for energy production. Of course these programs involve the costof the special containers and the cost of picking up and transportingraw organic waste. The more significant problem, however, is that theseprograms remain inconvenient to the users. In particular, the specialcontainer is typically kept in a garage because it must be large enoughto hold a week's worth of raw organic waste and because it smells by thetime that the pick up day arrives. The user must either travel regularlyto the garage to deposit organic waste or maintain interim collectionsof organic waste in the house. As with home composting, even users thatsupport the environmental goals of a municipal composting program mayonly separate some of their organic waste for composting. Municipalcomposting programs are also similar to home composting in that they aregenerally not useful for people living in apartments or condominiumssince the special container must be kept within the living area of eachunit where it takes up space, looks ugly and smells.

[0008] Because of these and other problems, consumers and other usersremain frustrated by the entire waste management and recycling process.

SUMMARY OF THE INVENTION

[0009] It is an object of the present invention or inventions to improveon the prior art. Another object of the invention is to reduce theextent to which odors and tasks such as moving, separating or storingorganic waste cause people to be frustrated with organic wastemanagement and recycling. The inventor has discovered that for users tobe satisfied with, and fully participate in, an organic waste managementand recycling process, most users need to have the sight, smell and bulkof raw organic waste immediately removed from their living or workingspace. Accordingly, another object of the inventions is to provide oneor more devices or processes for converting raw organic waste into aless offensive state or outcome, and to provide further processes forhandling or using the outcome. The following summary describes variousfeatures of the inventions to aid in understanding the exemplaryembodiments described later, but does not define or limit the inventionwhich may reside in a combination of some or all of the elements orsteps described in this section or other parts of this document.

[0010] In some aspects, the invention relates to converting organicwaste into one or more manufactures, materials or compositions ofmatter, which will be called outcomes. An outcome is created and existsat an intermediate point in time between when a person or machine deemsthe organic matter to be waste and when the matter is disposed of orinput into a process for using it, for example for compost, fuel or someother purpose. The outcome is more convenient and less offensive forusers to deal with than raw organic waste. In particular, the outcomemay be one or more of less smelly, more compact, lighter, cleaner tohandle, more visually attractive or easier to handle or store. Forexample, the outcome may be dried pieces of organic waste, each piecehaving no dimension longer than a few cm. Or the outcome may be a solidof substantially fixed shape, for example a brick, granule, pellet,sheet or disc etc., made of substantially dry pieces or organic matter.The pieces may be held together with a biodegradable or compostablebinder or may be closely packed or compacted. Further optionally, thesolids may be in a generally uniform or modular shape and size, maycontain masking odors, or may be colored. The outcomes are sufficientlydry to prevent or at least substantially reduce microbial growth and itsrelated odors. The outcomes remain substantially free of microbialgrowth for a useful period of time, for example between a few days andup to about one month, if kept out of contact with rain or soil but canbe decomposed intentionally. Such outcomes may be enjoyable to handle,leave minimal residue on the hands, and be efficiently packed forremoval to the curb or other destinations. The outcomes are moreconvenient to handle and less offensive than raw organic waste and soencourage users to divert organic waste from other garbage and toparticipate in composting or other programs. The outcomes can also bekept in the home or garage for extended periods of time, for examplefrom a few days to about a month or more, without creating intolerableodors and so may allow the user to take garbage out less often than oncea week at a savings of inconvenience to the user and cost to themunicipality.

[0011] In other aspects, the invention relates to processes forproducing the one or more outcomes. The processes for producing driedpieces of organic waste involve reducing raw organic waste to pieces anddrying the organic waste. The organic waste may be dried before or afterit is reduced and the reducing and drying may be performed by a varietyof processes or combinations of processes. There may optionally be othersteps such as washing; adding colors or odors; or wetting, for exampleto facilitate reducing the organic waste. The processes for producingsolids involve, reducing raw organic waste to pieces; producing amixture of the pieces, water and a biodegradable or compostable binderin proportions such that a solid may be formed from them; forming themixture into a shape; and, drying the shaped mixture. The mixture may beheated to aid in drying it or to enhance or activate the binder. Thebinder may be added to the water and organic waste or may be a substancealready present in the organic matter. Each step may be performed by avariety of processes. There may optionally be other steps such aswashing, wetting, draining, venting, moving, sensing, weighing,measuring, storing, freezing, compacting or adding additives such ascolors or odors. Some steps may also be repeated. For example, themixture may be formed into a shape, partially dried or heated, formedinto another shape, and then dried or heated further. Water, released asa liquid or vapor in some steps of the process, may be collected andrecycled for use in other steps of the process. An alternate processinvolves compacting the pieces of organic waste into a generally stablesolid shape. Pieces of wet or dried organic matter may optionally beproduced at an interim stage in the process of producing solids.

[0012] In other aspects, the invention relates to one or moreapparatuses capable of performing a waste processing process, such asone or more of the processes described above. In some cases, anapparatus has a processing module and a receiving module. The processingmodule may be stationary or temporarily stationary, may have one or moreof electrical, water, drain and venting connections and some or all ofthe machinery necessary to perform one or more of the processesdescribed above, and may be adapted to temporarily store raw orpartially processed organic waste or outcomes. The receiving module maybe portable, is adapted to receive organic waste, may have some of themachinery necessary to perform one or more of the processes describedabove, and may be adapted to temporarily store raw or partiallyprocessed organic waste. When the receiving module is connected to theprocessing module, the organic waste may be transferred to theprocessing module and one or both modules may be operated to perform awaste processing process such as one or more of the processes describedabove. The processing module may be freestanding, for example resting ona countertop or on a floor. Optionally, the processing module may belocated below a sink and the receiving module and processing module mayinterface through a hole in the sink, for example a conventional drainopening. Further optionally, a conventional under sink garbage disposermay be used to provide an input to a processing module. The processingmodule may also be built into a cabinet unit or a unit containing otherappliances. The receiving module and processing module may also beintegrated into a single unit. Such apparatuses provide a means forusers to quickly and easily convert objectionable raw organic waste intoone or more of the outcomes.

[0013] In other aspects, the invention relates to one or more householdorganic waste appliances. For example, an appliance has a receivingarea, which may be a portable receiving module, and a processing area,which may be a stationary or mobile processing module. The receivingarea is adapted to receive and collect organic waste in a plenum. Thereceiving area may also have a reducing implement for reducing theorganic matter and may optionally have an input for water to be added tothe plenum. The receiving area has one or more outlets for dischargingthe contents of the plenum and the processing area is adapted to receivethe organic matter discharged from the receiving area. An injecting andmixing device or devices may add binder to the organic matter in eitherarea. The receiving area may have a separating device for removing freeliquid water from the organic matter. Removed free liquid may be sent toa drain or saved for processing further organic matter. The receivingarea has solid or porous surfaces to form and support the organic matterin a shape. The receiving area may have openings for water vapor to exitthe processing area as the organic matter dries or means to retain thevapor, for example as a liquid which can be sent to a drain or re-usedto process more organic matter. The processing area may also haveheaters for heating the organic matter while it dries into a solid. Theprocessing area also has an opening for the solid to exit the processingarea.

[0014] In other aspects, the invention provides one or more processes ormethods for handling or extracting value from the outcomes. In somecases, the outcomes are used privately, for example by placing them in agarden or compost pile. In other cases, the outcomes are collected foruse in municipal composting programs. In other cases, a user may tradethe outcomes to an organization in return for credits, money or otherconsideration. The qualities of the outcomes facilitate storing,collecting or transporting them.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Various exemplary embodiments of the invention or inventions willbe described below with reference to the following drawings:

[0016]FIG. 1 is a flow chart of a first set of processes for makingoutcomes.

[0017]FIGS. 2A and 2B are photographs of a solid outcome.

[0018]FIG. 3 shows top and bottom views of another solid outcome.

[0019]FIG. 4 is a flow chart of a second process for making outcomes.

[0020]FIG. 5 shows various views of a receiving module of an apparatusfor practicing the process of FIG. 4.

[0021]FIG. 6 is a schematic representation of the receiving module ofFIG. 5 and schematic front and cut away views of a processing module ofan apparatus for practicing the process of FIG. 4.

[0022]FIG. 7 is a schematic representation of aspects of the interactionbetween the receiving module and processing module of FIG. 6.

[0023]FIG. 8 is a schematic cross-section of the receiving module andpart of the processing module of FIG. 6.

[0024]FIG. 9 is a chart of options for using outcomes.

DETAILED DESCRIPTION OF THE INVENTION

[0025] Outcomes and Methods for Producing Them

[0026]FIG. 1 illustrates a set of processes for converting organicmatter into one or more outcomes. A first process is shown in column A.The process begins by collecting organic matter to be processed. Thetype of organic matter collected may vary according to the intended useof the outcome. For example, if the outcome will be used in privatecomposting, the user may wish to collect only fruit, vegetable andcereal wastes typically composted at home. However, and particularly ifthe outcome will be used in municipal or commercial composting, theorganic matter may include all food wastes as well as absorbing paperproducts such as paper towels, tissues or napkins.

[0027] The collected organic matter is reduced in size by separating itinto pieces, for example pieces having no dimension greater than about 3cm or no dimension greater than about 1 cm. The matter may be reduced bya variety of means including shredding, mashing, crushing, milling andchopping. Screeners, classifiers or separators may be used to allowmatter below a desired size to exit the reducing process while retaininglarger matter that requires further reduction.

[0028] The organic matter is also dried to the point where microbialactivity substantially stops. The drying can be performed by a varietyof means, typically involving one or more of pressing, evaporation orsublimation, as known in the art of process drying. For example, theorganic matter may be dried using air bars, heaters, rotary dryers, airknives or internal impingement drums, suction dryers, drum dryers,rotary tubes or bed dryers. As shown in column A, the drying may occurafter the organic matter is reduced in size. But the drying may alsooccur before the matter is reduced or at least partially while theorganic matter is being reduced. The preferred order of steps may bechosen in view of the specific methods chosen to reduce and dry theorganic matter.

[0029] Additives may be added to the organic matter to give the matter amore pleasant appearance or odor. For example, food coloring or dies maybe added to make the organic matter green or some other desirable color.Highly aromatic, and preferably biodegradable, substances such as coffeegrinds or vanilla extract may be added to give the matter a desirablesmell. As shown in column A, the additives may be added after theorganic matter is reduced but before it is dried. The additives may alsobe added before the organics are reduced or after they are both reducedand dried. The preferred time to add additives, if any, may be chosen inview of the qualities of the additive and whether it is easier to mixinto dried or un-dried organics.

[0030] At the end of the process, substantially dry pieces of organicmatter are produced as a first outcome. Because the outcome is in piecesit can be packed with a reasonably high density into a receptacle forstorage or transport. Because the outcome is dry, microbial activity hassubstantially stopped and so the pieces are generally odorless. However,the outcome will re-absorb moisture from the atmosphere in time. Theprecise extent to which the matter is dried may be chosen depending onhow long the user wants the outcome to remain generally odorless underthe expected conditions of storage. For example, the user may intend tostore the outcome for only a few days during a dry season before placingthe outcome on a compost pile for decomposition. In contrast, anotheruser may wish to store the outcome for a few weeks during a moist seasonbefore taking the outcome to a commercial composting plant. The firstuser will require significantly less drying than the second user toensure that the outcome remains generally odorless until the outcome isintentionally decomposed.

[0031] Column B shows another process for creating an outcome ofsubstantially dry pieces of organic matter. The process of column B issimilar to the process of column A and much of the description aboverelating to column A applies to column B. The process of column Bdiffers, however, in that water is added to the organic matter before itis reduced to pieces. The additional water enhances the performance ofmany reducing methods, such as chopping, and the amount of water addedmay be chosen in view of the requirements of the reducing method. Afterthe organic matter is reduced, excess water is removed. The excess watermay be removed using any of the drying methods mentioned above. However,since a larger quantity of free liquid water is to be removed, otherprocesses such as spinning, centrifuging or pressing against a screenedor porous plate may be more efficient. Through the course of adding andremoving water, the organic matter is washed to some extent and may thenbe easier to dry to a generally odorless state.

[0032] The process of column B also differs from column A in that,although additives may still be added at any stage, any additive addedbefore the liquid water is removed may be partially washed away. It isalso not optional in the column B process to dry the organic matterbefore it will be reduced in size. Further, the first three steps in theprocess of column B (inserting organic matter, adding water and reducingthe organic matter to pieces) may optionally be performed by an ordinaryunder sink garbage disposal unit. Such disposal units, however, uselarge amounts of water and may make the organic matter very fine andincrease the amount of organic matter that washes away when liquid wateris removed.

[0033] The process of column C can be used to convert the outcomecreated by the process of columns A or B into a different outcome. Thedifferent outcome is a solid of substantially fixed shape made up ofpieces of organic matter dried to be generally odorless. The column Cprocess is illustrated as a separate process, but it may also be mergedwith the process of either column A or B. In merging these processes,the steps of removing and collecting the dry pieces of organic matter atthe end of columns A or B and the beginning of column C may be deleted.However, to produce a solid of a specified size and shape, the amount oforganic matter used must be within a range determined by the tolerancesof the size and shape specifications. But since users may randomlygenerate more or less organic matter over any particular period of time,the first step of columns A or B may be changed to collecting andstoring organic matter until an appropriate amount of organic matter iscollected. The organic matter can be stored in a sealed container,refrigerated or frozen to reduce odors while waiting for an appropriateamount of organic matter to be collected. Alternately, the appropriateamount of organic matter can be accumulated in the form of dry pieces oforganic matter between the process steps of columns A or B and C. Inthis embodiment, the process steps of columns A or B are performedwhenever the user wishes to process organic waste and with any amount ofwaste that the user wishes to process. The resulting dry pieces arestored until the required amount of organic matter, as determined byweight or volume or both, has been collected in the form of dry pieces.Since the dry pieces can be densely packed and are generally odorless,it may be easier to store and collect the required amount of organicmatter as dry pieces than as raw waste. Further alternately, the processmay be performed with any arbitrary amount of organic matter andallowing the size or shape of the outcome, or number of outcomesproduced, to change accordingly.

[0034] Referring now to column C, the pieces of organic matter are mixedwith water and a binder to form a slurry. The binder is capable ofholding the pieces of dry organic matter together in a solid ofgenerally fixed shape when stored in a protected environment, such asinside a garage or building. But the binder breaks down when exposed tothe elements so that the solid may decompose or revert to loose piecesof organic matter. For example, the binder may be an organic substancesuch as egg whites, honey or a carbohydrate such as a starch or flour orsugar. The specific amounts of binder and water required may be selectedin view of the binder used or other factors. For example, when flour isused as a binder for pieces of mixed organic kitchen waste, betweenabout 2% and 15% flour by volume can be added. When using these ratios,the volume of the flour is measured when the flour is dry and the volumeof the pieces of waste is measured with the pieces in a slightly wetstate resulting from mixing the pieces with water and then draining awayexcess water through a sieve. The same ratios may also be used if thevolume of the pieces of organic matter is measured dry. Adding an amountof flour near the high end of the range produces a more tightly boundsolid and may be used for making thin sheet outcomes, when using largepieces of organic matter, or when the outcome will be required to remaindurable for long periods of time, for example a month or more. Amountsof flour near the high end of the range may also cause the solid to dryfaster. Amounts of flour near the low end of the range may be used formaking brick outcomes, when using small pieces of organic matter or whenthe outcome will be composted a short time, for example about a week,after it is made. For some organic wastes, the waste itself may providea sufficient quantity of binder such that no additional amount of binderis required. The amount of water added is such that the slurry can beformed manually into shapes and will generally hold a freestanding shapeof a few cm high. Any additives may also be added during or after thisstage if they have not been added earlier. Instead of collecting batchesof substantially dry pieces of organic matter sufficient to make a solidof a desired size, all steps up to and including the step of forming aslurry in column C may be performed in batches until an amount of slurryis collected sufficient to make a desired solid.

[0035] The slurry is formed into a shape and dried into a solid. Theshape may be merely a mound or irregular sheet formed manually on aplate. However, a mold with at least a bottom and sides will produce asolid of more uniform shape and size. For example, FIG. 2A shows a brick10 formed manually on a sheet. Such a brick 10 may also be formed in amold and may be made with a height of between about 1 and 5 cm, a depthof between about 4 and 10 cm and a length of between about 10 and 25 cm.Such a brick 10 is a pleasant weight, size and shape to handle and canbe densely packed into boxes or piles easily. However, such a brick 10takes a significant amount of time to dry throughout and its sides 12may become slightly dished during drying. FIG. 2B shows various bricksor solids of different shapes. The brick in the upper left hand cornerof FIG. 2B has holes through it from top to bottom which reduces therequired drying time and distortion to the sides while drying. FIG. 3shows a plate 14 that dries faster and more evenly than the brick 10.The plate 14 may be between about 3 mm and 2 cm thick, is pierced withholes 16 and has an undulating upper surface 18 and lower surface 20.The plate 14 is formed in a mesh-walled mold and the distance that watervapor needs to travel to leave the plate 14 is shorter and more nearlyconstant than for the brick 10. Outcomes may also be formed in a rangeof other shapes such as briquettes, flat sheets of between about 3 mmand 2 cm thick, granules, fibers or flakes. In addition to simple ormesh-sided molds, the desired shapes may be formed in other devices suchas isostatic compacting presses, powder compacting equipment, ortableting or uniaxial presses. Compacters or presses may also be used toform the dry pieces of organic matter directly into a generally solidshape either with or without adding water or a binder to the pieces.Pressing the slurry into a porous mold also aids in drying the solid. Ifdesired, the user could also use the slurry itself as an outcome,although it will be an outcome of short duration.

[0036] As for the dry pieces of organic matter, the solid outcomes aredried to a moisture content that makes them durable in anticipatedenvironmental conditions when stored not in contact with liquid water orsoil for a desired period of time that may be up to or over one month.While the slurry is dried into a solid, it may also be heated either toincrease the rate of drying or to improve the activity of the binder.Heat can be provided by a number of methods that either heat the slurrydirectly or through the mold or by a combination of methods. The slurrymay be heated to between about 35 C to 100 C or between about 35 C and50 C. If the organic matter includes bone, a higher temperature, forexample 150 C or more, may be used to help solidify the gelatin in bonewaste. As examples, heat can be provided by steam, convection, thermaloil, combustion, fluid compression, electricity, microwave,contact/dielectric, conduction, radiant or infrared. The heat may alsokill some additional microorganisms or cause changes in the chemicalstructure of the organic waste and extend the time for which the solidremains durable. Treating the organic matter with ozone or UV radiationmay also kill some additional microorganisms and extend the time forwhich the solid remains durable.

[0037] The appropriate dryness of the solid, or the process parametersthat produce the appropriate dryness, can be determined by trial anderror for storage in various environments. Once the appropriate drynesshas been determined for a desired solid size and shape and storageconditions, that dryness level can be obtained by repeating the processwith the empirically determined parameters, by checking the dryness ofthe solid from time to time with a moisture content meter while it isdrying, or by noting visual cues indicating a state of dryness. Visualcues may include dishing or cracking of some surfaces, changes in coloror changes in the shape or size of the solid. Changes in size or weightof the solid may also be correlated with dryness and measured from timeto time while a solid is drying to determine when the solid issufficiently dry. The drying process may be machine controlled, forexample by linking a moisture content meter or electronic scare to aprogrammable logic controller configured to stop the drying process whena target weight or moisture content is reached. A moisture content of20% or less, or 15% or less, or between 5% and 15%, the percentagecalculated based on the weight of water in the outcome divided by theweight of the outcome including the water in it, may be present in thedried outcome. For example, the moisture content of two sample outcomebricks were tested using an oven drying method similar to ASTM D644:M99“Standard Test Method for Moisture Content of Paper and Paperboard byOven Drying”. The measured moisture contents were about 11% and 5% basedon the original sample weight or about 12% and 6% based on the ovendried weight.

[0038]FIG. 4 shows another process for producing solid outcomes. Theprocess of FIG. 4 resembles a combination of the processes of columns Band C of FIG. 1 but differs in that an intermediate outcome ofsubstantially dry pieces of organic matter is not produced. Accordingly,some process steps of Columns B and C of FIG. 1 are not required.

[0039] The process of FIG. 4 begins by collecting organic matter to beprocessed. Water may be added to the organic matter if necessary ordesired. As mentioned above, some reducing processes operate better inthe presence of water but the organic matter itself may contain asignificant amount of water that will be released as soon as the organicmatter is reduced. Accordingly, in some cases the organic mattersupplies water for the process.

[0040] The organic matter is reduced to pieces and the water content ofthe organic matter may then be adjusted. For example, if an excess ofwater was present to facilitate reducing the organic matter, then wateris typically removed after the organic matter is reduced. The watercontent may be adjusted to a level that is sufficient, or slightly morethan sufficient, for the intended binder. The water content may also beadjusted to a pre-selected state of wetness to facilitate the remainingprocess steps. Such a pre-selected state may also be achieved by addingan appropriate amount of water before the organic matter is reduced.

[0041] After the organic matter has been reduced, it is checked to seeif there is an appropriate amount of organic matter for making a desiredsize, shape and number of outcomes. For example, the weight, volume orboth of the organic matter may be measured and compared to apre-determined weight, volume or both known to produce a desired numberof solids of a desired size and shape. This step is typically easier toperform at a pre-selected state of wetness since variation in wetnessdoes not need to be considered. But this step may also be performed witha random degree of wetness, for example by allowing the pieces to settleor pressing the pieces to the bottom of a container and measuring theirvolume. If an appropriate amount of organic matter is present, then theprocess continues. If not, then more organic matter is collected andpartially processed until an appropriate amount of organic matter iscollected. As discussed above, the user may also determine how much raworganic waste is required to form the desired outcome and commence theprocess only with the required amount of organic waste. In this case, itwill not be necessary to check for an appropriate amount of pieces laterin the process but it may be necessary to store raw waste temporalityuntil an appropriate amount is accumulated. The stored organic mattermay be frozen or otherwise prevented from producing odors while waitingfor an appropriate amount of organic matter to be collected.Alternately, the process may also be run with any arbitrary amount oforganic matter. In this case, however, the number, size or shape of theoutcomes may vary. For example, if a brick 10 will be formed in an openpan, the height of the brick will vary in relation to the amount oforganic matter used. If a plate 14 will be formed between upper andlower forms, then the width or length of the plate 14 may vary with theamount of organic matter used.

[0042] A binder and, optionally, any other additives may be mixed withthe organic matter. However, in some cases the organic matter itself maycontain significant amounts of binders and so no additional binder isadded. Although FIG. 4 shows the binder being mixed in after the watercontent is adjusted, the binder may optionally be mixed in before thewater content is adjusted. If the water content is adjusted by removingliquid water, then some of the binder will be washed away, but it may beeasier to mix in the binder while the water content is higher. As forthe other processes, additives such as food coloring or dies or pleasantaromas can be added at various points in the process and need not beadded where indicated in FIG. 4. Once the slurry has been created, theremaining process steps are the same as described for Column C of FIG.4.

[0043] In the absence of any special equipment, the processes above canbe performed using common kitchen appliances. For example, to performthe process of FIG. 1, Column A, the user may place organic waste into ablender. The user turns the blender on until the user can see that theorganic matter has been chopped into small pieces. The user may drop anyadditives into the blender while the organic matter is being chopped.The user then pours the pieces out of the blender onto a cooking sheetand heats them in an oven until they are dry. When the pieces are dry,the user takes the cooking sheet out of the oven and dumps the drypieces into a bag, bucket or other container. The process of FIG. 1,Column B can be performed in essentially the same way except that theuser pours water into the blender with the organic waste. After theorganic matter is chopped up, the user can remove the liquid water byallowing the pieces of organic matter to settle and then pouring excesswater out of the top of the blender. Alternately, the user can pour thecontents of the blender into a sieve and keep only the retained piecesof organic matter. To perform the process of FIG. 1, Column C, the usermay collect the dry pieces of organic matter in a mixing bowl. The userthen pours in water, a binder and any desired additives, places thebeaters of a mixer into the bowl and turns the mixer on until a slurryforms. The user may then pour the slurry into a bread or cake pan andput it in an oven for drying. Once dry, the user takes the pan out ofthe oven and turns it over so that the solid drops out. For the processof FIG. 4, the user may place water and organic matter in a blender andturn the blender on to reduce the organic matter to pieces. Ifnecessary, supernatant water can again be poured of the top of theblender or the contents of the blender strained to remove liquid water.The user then pours the pieces of organic matter into a mixing bowl. Ifthe pieces are too dry at this point for mixing with the binder, thenthe user adds water as necessary. The user then completes the process asdescribed for the end of the process of FIG. 1, Column C. In all ofthese processes, if the user wishes to collect a certain amount of raworganic matter before processing it, the user may keep odors low whileaccumulating the waste organic matter by collecting it in a sealedcontainer or in a container kept cool in a refrigerator or frozen in afreezer.

[0044] As an example, the inventor collected household kitchen waste andreduced it in a blender with an excess of water until the pieces oforganic waste were not more than about 3 mm in any dimension. Theinventor then emptied the waste into a sieve to remove excess water. Theinventor then collected more household waste and similarly blended itwith water and poured it in the sieve. When the sieve contained about650 cubic cm of pieces, the pieces were mixed with a full tablespoon offlour for a binder, and formed into a brick shape of about 4 cm by 8 cmby 20 cm. The pan was heated in an oven at 50 C for about 32 hours. Theresulting brick remained dry to the touch and substantially odorless forat least about three weeks. In another example, the inventor similarlyproduced pieces of organic matter but having no dimension more thanabout 2 cm. The pieces were poured from the sieve into cheesecloth andpressed by hand to remove more water. The pieces were then mixed withflour and spread out in a sheet about 1 cm thick in a pan. The inventorpoked holes of about 7 mm in diameter through the sheet. The sheet washeated in an oven for about 5 hours at about 50 C. The resulting sheetremained dry to the touch and substantially odorless for at least abouttwo weeks.

[0045] For further example, discarded organic matter, such as kitchenwaste, may be chopped by machine or by hand into chunks of about 5 cm orless in their longest dimension. The organic matter may be, for example,vegetable scraps, vegetable and bread scraps, vegetable and bread scrapsand absorbent papers, cooked leftovers or vegetable scraps and cookedleftovers. The chunks are placed in a mixing bowl and their volumemeasured without compacting them. About 125 mL of water per liter ofchunks and about 125 mL of flour per liter of chunks is added to thebowl. Colouring or odourous substances may also be added. Further, aboutone teaspoon of sugar per liter of chunks may be added to the bowl. Thesugar makes a finished solid more brittle, which tends to reduce thetime required to compost it, and also reduces the required drying time.The contents of the bowl are blended for about 30 seconds or until thecontents become a rough paste. Additional water may be added if a pastewill not form. Alternately, adding about 250 mL of water per liter ofchunks to the bowl initially, instead of 125 ml of water per liter ofchunks as stated above, generally avoids the need to add additionalwater later to create a paste. However, additional water or an increasedinitial amount of water is often not needed, particularly when theorganic waste includes cooked leftovers or other waste having a highwater content.

[0046] The paste is transferred to a sieve or cheesecloth and pressed byhand to release water. The water reduced paste is then transferred to aflat cooking sheet and formed, for example by hand or with a spatula,into a block or other shape. The cooking sheet and shape are placed inan oven heated to between 200 and 300 F for about 30 minutes. After thistime, the shape is retrieved from the oven and pressed further into asmaller or more geometric shape. The solid may be re-shaped since theflour or other parts of the mixture will have started to bind orcoagulate making a shape easier to form. Also, air pockets may haveformed that may be released allowing a smaller shape. Holes, for exampleholes of about 0.5 cm diameter spaced roughly 1 to 2 cm apart, may bepoked through the shape with a dowel at this stage to speed futuredrying. The shape is returned to the oven. The oven is turned off, butthe door left closed allowing the shape to dry as the oven loses heat tothe environment.

[0047] Drying may also be accomplished without heating. For example, theslurry may be placed in a mold and left to air dry. Drying will befaster if the mold is porous, for example if at least some sides aremade of screen or cloth. The porous mold provides more surface area formoisture to leave the solid as well as allowing some liquid water todrip out. Drying the paste outdoors, but out of contact with rain, in aporous mold produces a sufficiently dry solid particularly in dry orsunny weather without using energy for heating.

[0048] In all of the processes described above, water released in somesteps may be recycled for use in other steps. For example, water isreleased as a liquid or vapor during drying steps and as a liquid duringsteps of removing liquid water or adjusting the moisture content ofpieces of organic matter. This water may be collected and used, forexample, in steps of adding water, or mixing pieces of organic wastewith water. In general, the steps that require water precede the stepsin which water is released. Accordingly, an initial supply of water isrequired to perform a first batch, if a process is performed wholly orpartially as a batch process, or to start a continuous process and run acontinuous process before recycled water is available. Although aninitial supply of water may be required, the processes produce wateroverall since the moisture content of the organic matter is reduced. Forthis reason, not all releases of water need to be captured to sustain arepeated batch or continuous process. For example, vapors producedduring drying steps may be captured since they provide relatively cleanwater which can be stored without further treatment until requiredwithout excessive growth of microorganisms in the water. Alternately,recycling water released in steps of removing liquid water or adjustingthe water content of the pieces of organic matter reduces the amount ofdissolved or very small pieces or organic matter that are not capturedby the process. However, this water may required treatment, such as UVor chemical disinfection or refrigeration, if it will be stored forextended periods of time before reuse and may required adjustment, forexample by filtration, clarification or other separation processes, toprevent it from becoming highly concentrated with organic matter.Organic matter separated from the recycled water may itself be recycledto and re-enter the process as collected organic matter.

[0049] Although the processes described above result in a dried outcome,the processes may optionally be stopped at other phases. For example,the process may stop when a slurry is present. The slurry may be usefulwhen a user wants an outcome for immediate use that decomposes veryrapidly, since the slurry will decompose faster than raw organic matter.

[0050] Apparatus for Producing Outcomes

[0051] FIGS. 5 to 8 show an apparatus 30 for producing solid outcomes.Referring first to FIG. 5, the apparatus 30 has a receiving module 32for collecting organic waste. The receiving module 32 has a base 34 andsides 36 which create an internal space for collecting and holdingwaste. A lid 38 is hinged to one of the sides 36 and can be closed togenerally seal the space inside the receiving module 32 or opened toallow the user to insert waste. The lid 38 may seal the space inside ofthe receiving module 32 to a sufficient degree so that odors are notsensed by users from organic matter that may remain in the receivingmodule 32 for most of a day. The lid 38 is balanced to remain open whenfully opened and has a finger depression 40 to allow the user to liftit. A handle 42 flips up or down for carrying. When the handle 42 isdown it does not protrude beyond the sides 36 of the receiving module32. An apparatus 30 may have a plurality of receiving modules 32. Thereceiving modules 32 may be dispersed throughout a household orbusiness, and kept at collection points in a kitchen, dining room,bathroom or wherever organic waste is produced. The receiving module 32may have an exterior made of stainless steel or other attractive andsafe materials. Many other shapes may also be used for the receivingmodule 32. For example, in some embodiments, the handle 42 may protrudefrom beyond the sides 36. Two handles 42 may be used on opposed sides 36to make the receiving module 32 ambidextrous. The receiving module 36may be made to have a removable lid 38 and height, for example of 25 cmor less, such that it may be periodically washed in the bottom drawer ofa dishwasher.

[0052] Referring to FIG. 6, the apparatus 30 also has a processingmodule 44 and a system controller 50. The system controller 50 managesthe operation of the processing module 44. The system controller 50 ismounted in a location accessible to the user and contains controls foroperating or programming the apparatus 30 and an interface that givesthe user feedback and prompts the user to make any required choices oractions. For example, the system controller 50 gives the useroperational and standby status information and notice of any need forfresh supplies such as binder. In other embodiments, householdparticulars may be entered into the system controller such as the timeor user's address. The system controller 50 may also be programmed tokeep track of the local garbage pickup schedules and remind the userwhen garbage needs to be put out. The system controller may also allowthe user to specify preferences or over-ride pre-programmed routines tochange the operation of the processing module 44. For example, in someembodiments the user may specify the desired size, shape or form oroutput, the amount of binder to use, whether to use any additives suchas colors or odors, the moisture content for the output, or whether theoutput should be wrapped, bagged, or bar-coded to contain householdinformation.

[0053] The processing module 44 may be a freestanding unit as shown. Ifdesired, however, the processing module 44 may alternately be installedunder a kitchen counter. When the processing module 44 is installedunder a counter, the top 46 of the processing module 44 may sit in ahole in the counter either flush with the counter top or slightly aboveor below it. Further alternately, the processing module 44 may beinstalled under a sink with some alteration. In particular, portions ofthe processing module 44 above the sink bottom 48 shown in FIG. 6 arediscarded or relocated to locations below the sink bottom 48. A hole isprovided in the sink bottom 48 so that receiving module 32 may stillcommunicate as necessary with the processing module 44. A plug, notshown, seals the hole when the apparatus 30 is not in use. Alternatelyor additionally, parts of the processing module 44 that are accessibleto the hole are made waterproof and configured so that water will notrun out of the sink through the processing module 44. When theprocessing module 44 is mounted under a counter or sink, at least theuser interface parts of the system controller 50 may be separated fromthe remainder of the processing module 44 and mounted in a locationconvenient to the user.

[0054]FIG. 7 shows aspects of how the receiving module 32 interacts withthe processing module 44. In part A, the receiving module 32 is placedon a gate 52 of the processing module 44. The user may then push abutton on the system controller 50 which causes a motor, solenoid, orhydraulic or pneumatic cylinder or other mechanism, not shown, to openthe gate 52. Alternately, the processing module 44 can be configuredsuch that the gate 52 opens when user passes his or her hand in front ofa motion detector (infrared sensor) on the processing module 32. Furtheralternately, the processing module 44 can be configured such that thegate 52 opens when a sensor on the processing module 32 detects thepresence of the receiving module 32.

[0055] As shown in FIG. 7, Part B, with the gate 52 open, the receivingmodule 32 slides into a track 54 in the processing module 44. A scrubber56 in the track 54 applies sufficient force to hold the receiving module32 part of the way down the track 54 if desired. The receiving module 32may be left in this position, optionally with the lid 38 left open,while waste is being generated. In this position, the receiving module32 provides a convenient counter top, or counter top height, place todeposit waste as it is produced. Optionally, the receiving module 32 maybe insulated and fitted with a small refrigeration unit that is turnedon only when the lid is closed. The refrigeration unit may be powered bybatteries which are recharged automatically when the receiving module 32is in the track 54. Alternately, the refrigeration unit may be powereddirectly from the processing module 44 when the receiving module 32 isin the track 54. The refrigeration unit prevents significant odors fromdeveloping if waste is left in the receiving module 32 for extendedperiods of time.

[0056] When the user wishes to process the waste, the user closes thelid 38 if it is open and pushes the receiving module 32 to the end ofthe track 54 where it engages with the processing mechanisms 58 of theprocessing module 44. Pressure contacts, not shown, or other sensorssense when the receiving module 32 is fully engaged and signal the gate52 to close. The pressure contacts also send a signal indicating thatthe receiving module 32 is engaged to the processing module 44.Alternately, the user may be required to move a lever, rotate a knob,flick a switch that triggers a solenoid or perform some other action toengage the receiving module by physically connecting it to theprocessing module 44. In this case, the signal indicating that thereceiving module 32 is not sent until a sensor confirms that thephysical connection has been made. The processing module 44 isconfigured to only permit process steps involving the receiving module32 to occur while the receiving module 32 is engaged. However, where theuser performs a function to physically connect the modules 32, 44, thatfunction may also be used to power a function. For example, a leverpulled by the user to connect the modules 32, 44 may also activate therelease of an amount of binder into the receiving module 32. To do this,the binder may be located in a tube that is compressed by a plungermechanically linked to the lever. Adding the binder to the receivingmodule 32 may increase the amount of binder that is washed away when thesolid is dewatered, but may also allow for better mixing of the binderwith the organic matter.

[0057] After the waste is transferred to the processing module 44, thereceiving module 32 will be empty and the system controller will causethe gate 50 to open. The user then reaches into the processing unit 44,lifts the handle of the receiving module 32 and lifts it out. The userthen pushes a button on the system controller 50 to instruct it to closethe gate 52. Optionally, the processing module 44 may be fitted withsensors that signal the system controller 50 to close the gate 52 whenthe receiving module 32 has been fully removed. As discussed below, theinside of the receiving module 32 will have been rinsed with water atthe end of the processing steps, optionally with heated water or watercontaining a disinfectant. If desired, however, the user may also spraythe inside of the receiving module 32 with a cleaner, anti-microbialagent or scent-neutralizer after removing it from the processing module44.

[0058] The apparatus 30 may also have the components of the receivingmodule 32, processing module 44 and system controller 50 merged into asingle appliance body. In this case, some elements required to connectthe receiving module 32 to the processing module 44, as described above,are not required. For example, components of the receiving module 32 maybe permanently located in the position shown in Part C of FIG. 7. Thegate 52 and track 54 and other components may be removed and the lid 38of the receiving module 32 made to open directly to the outside of theapparatus. In that configuration, a user brings all waste to beprocessed to the apparatus 30 for insertion through the lid 38. However,an alternate means of causing the processing module 44 to start isrequired since the action of engaging the receiving module 32 no longerperforms that function. For example, the lid 38 may be provided with asensor which signals for processing to start every time that the lid 38is closed. Alternately, the controller 50 may be provided with a startbutton and the user required to indicate when processing should start byactivating the button, a lever or similar device. Further alternately,the receiving module 32 may be fitted with weight or level sensors andthe controller 50 adapted to start processing when a threshold weight orheight of organic matter is present in the receiving module 32. Thesemethods may also be combined or other methods used. For example,processing may begin when a threshold weight of organic matter isreached unless the user bushes a button or switch to start processingbefore the threshold is reached. Such an integrated apparatus 30 mayalso be placed in its entirety under a sink. In such a case, the lid 38may protrude through the sink so that water does not drain out of thesink through the apparatus 30 when not intended and the normal sinkdrain retained. Also, the presence of the lid 38 may encourage users notto put soap or cleaning chemicals that may be used in a sink into theapparatus while still making it possible to add water to the receivingmodule 30 by simply turning on the tap to the sink while the lid 38 isopen. However, the apparatus 30 may also be used without a lid 38, orwith a lid 38 or other closure that may be attached or closed only whileprocessing waste, and receive matter directly from the ordinary sinkdrain. In this case, since there will be times when very large amountsof water are discharged from the sink which would otherwise require veryfrequent processing, the receiving module 32 may be provided with alarge screened outlet to drain partway up its side. In that way, somewater, as is useful for processing, may remain in the receiving module,while excess water flows through. The outlet is closed while processing.Optionally, a diverter may be inserted between the sink and theapparatus 30. The diverter allows solid matter to drop to the apparatus30 while passing excess water to a drain.

[0059]FIGS. 6 and 8 show the processing mechanisms 58 of the processingmodule 44 and working parts of the receiving module 32 in greaterdetail. The receiving module 32 has a frame 60 that may be made, forexample, of stainless steel and supports the other parts of thereceiving module 32. A perforated liner 62 lines the inner space whereraw waste is held. The holes in the perforated liner 62 are sized sothat only organic matter that has been reduced to a desired size willpass through them. Blades 64 are mounted inside of the perforated liner62 for reducing the organic waste to size. In some embodiments, theblades 64 are covered by blade covers (not shown) which are withdrawnwhen the receiving module 32 is engaged to protect against the usertouching the blades 64 while inserting waste. Two sets of blades 64 areshown, but a single set of blades 64 may also be used.

[0060] The blades 64 are mounted to a male blade power feed 66 thatengages a female blade power feed 68 when the receiving module 32 isengaged in the processing module 44. The female blade power feed 68 isdriven by a blade pulley 70 that is attached to a motor 74 (shown onlyin FIG. 6) through a main axle 72. The blades 64 may differ in size andshape. Alternately, each blade 64 may be attached to a different one oftwo concentric male blade power feeds 66. Each of the two male powerfeeds 66 engages a different one of two concentric female blade powerfees 68 when the receiving module 32 is engaged. Each of the two femalepower feeds 68 may be driven by a different one of two blade pulleys 70.The two blade pulleys 70 may be attached to the same main axle 72.However, either the two female power feeds 68 or the two blade pulleys,or both, may have different diameters such that each blade 64 moves atdifferent speeds. By the variations in blade size, shape or speed, eachblades 64 may be optimized to act on a different size or types oforganic matter.

[0061] The main axle 72 also drives a water pump 76 that is connected,when the receiving module 32 is engaged, through a water junction 78 anda water input line 80 to one or more water inlets 82 opening into thereceiving module. Thus to wet and reduce organic matter in the receivingmodule, the motor 74 is turned on to spray water into the receivingmodule while driving the blades 64. Alternately, the water pump 76,water junction 78, water input line 80 and water inlets 82 may beomitted. In that case, the user may put water into the receiving module32, for example by placing it under a tap in a sink, before engaging thereceiving module 32 with the processing module 44. After processing, thereceiving module 32 may be taken back to the sink for rinsing out or putinto a dishwasher.

[0062] Reduced pieces of organic matter and water passes through theperforated liner 62, through water take out channels 84 and drainconnections 86 to the processing module 44. Drain valves 88 in theprocessing module 44 are open while the motor 74 is turned on. A drainsensor 90 senses when pieces of organic matter are no longer passinginto the processing module 44 and then signals the motor 74 to stopafter a short period of time so that the receiving module 32 will berinsed with water from the water jet. In some embodiments, the rinsingwater is heated or injected with a disinfectant. Once the receivingmodule 32 is empty, the gate 50 opens and the user may remove thereceiving module 32.

[0063] The water and pieces of organic matter pass into a formingchamber 92 in the processing module 44. As this happens, binder, or amix of binder and other additives, is injected through a binder inlet94. The binder is drawn from a binder reservoir 108 (shown in FIG. 6)which the user can refill or replace from the front of the processingmodule 44. The binder is mixed with the pieces of organic matter by theforce of its injection and the turbulence of the water entering theforming chamber 92. Alternately, the binder inlet 94 and reservoir 108may be omitted and the user may deposit binder into the receving module32 before connecting it to the processing module 44. Furtheralternately, the binder inlet may be adapted to mate with an inlet ofthe receiving module 32 such that binder is injected in the receivingmodule 32 on or directly after engaging the modules 32, 44 together. Bythese alternatives, the binder or other additives are mixed with theorganic waste as it is reduced in size.

[0064] The mix of pieces of organic matter, binder and water lands ontoa screen floor 96 in the forming chamber 92. Free liquid water flowsthrough the screen floor 96 and past a drying rod assembly 98 and leavesthe forming chamber 92 through a forming chamber drain 100. A slurry ofpieces of organic matter, binder and surface held water remain on top ofthe screen floor 96 and flow by gravity into a shape defined by thescreen floor 96, walls of the forming chamber 92 and drying rod assembly98.

[0065] A weight sensor 116 communicates with the screen floor 96 andsenses the weight of the pieces of organic matter (and water attached tothem) resting on the screen floor. The system controller 50 compares thesensed weight to specifications relating to the output through analgorithm that determines whether enough organic matter is present. Thealgorithm may simply compare the weight of the organic matter to aminimum weight for the selected outcome. Alternately, the systemcontroller 40 may allow the user to indicate what sort of waste has beenentered. The indication may be made, for example, by pushing one of aset of buttons indicating whether the bulk of any load of matter is oneof raw vegetables, cereals, absorbent paper, cooked leftovers or otheroptions each time a load of matter is transferred from the receivingmodule 32. The system controller tracks the additional weight sensed byweight sensor 116 after each load of organic matter is added to theprocessing module 44 and a parameter indicating which button was pushedwhen the organic matter was transferred from the receiving module. Thealgorithm includes parameters corresponding to an estimated moisturecontent assigned to the different types of waste, calculates theestimated moisture content of the total amount of organic matterpresent, and adjusts the threshold weight according to a formulaaccounting for the estimated moisture content and the selected outcome.The outcome or output specifications are either preset or programmed bythe user. The system controller 40 prevents further process steps fromoccurring until enough organic matter is collected. If the systemcontroller 50 determines that an appropriate amount of organic matterhas been collected while more organic matter is still being reduced inthe receiving module 32, the reducing operation is shut down until theoutput is made and removed from the processing module 44. While theoutcome is being made, the system controller 50 may be programmed torelease the receiving module 32 to the user. Alternately, the user mayover-ride all of these functions or program the system controller sothat further process steps occur right after the receiving module 32 isemptied. In this case, random sizes, shapes or numbers of outcomes willbe produced.

[0066] When the process is to continue, heating elements 102, which maybe electrically powered radiant, infrared or microwave heaters, heat theslurry directly and indirectly by heating the drying rod assembly 98. Asthe slurry dries into a solid, moisture is drawn off through a moisturescavenging port 104. When a moisture sensor 106 indicates that thesolidified slurry has reached a desired moisture content, the heatingelements 102 are turned off. Prior to heating, the slurry may optionallybe pressed. To press the slurry, the top of the forming chamber 92 maybe fitted with a plate, not shown, movable to push the slurry againstthe screen floor 96 for a time and then retract. The extension of theplate may be stopped when a set distance is reached if the solid willalways be of generally the same size or when a certain pressure isreached. The pressing plate may be moved automatically and be, forexample, electrically powered. The pressing plate may also be movedmanually, for example by providing a leaver on the side of theprocessing module 44 mechanically linked to the pressing plate.

[0067] Moisture collected through moisture scavenging port 104 duringdrying may be released to atmosphere either directly or through filtersto remove odors. Alternately, referring to FIG. 6, the collectedmoisture may by converted into liquid water by connecting the moisturescavenging port 104 to a moisture input 130 to a moisture liquefyingdevice 132 such as a condenser, dehumidifier or other device. Themoisture liquefying device 132 may also include or be connected inseries, to the gas flow, with an odor reducing device 140, such as a gasporous membrane module or activated charcoal canister, to reduce odorsbefore air or other gases are discharged through an exhaust 142. Liquidwater produced from the vapor may be sent through a recycled vapor drain134 to a household drain and leave the processing module 44.Alternately, the liquid water may flow through the recycled vapor drain134 to a receptacle 136 for collected water within or connected to theprocessing module 44. Similarly, forming chamber drain 100 may beconnected to a household drainpipe such that free liquid water leavesthe processing module 44 or to a forming chamber water input 138 toreceptacle 136. The user may empty the water in the receptacle 136 fromtime to time or the receptacle 136 may be fitted with an overflow 144 toa household drain. The receptacle 136 may be closed, fitted with filterson any outlet, treated with ozone or UV radiation, chilled or otherwisetreated or configured to minimize the creation or escape of odors. Thereceptacle may be connected to the water pump 76 through a water supplyline 146 and sized to be able to provide the source of water to wet theorganic matter in the receiving module 32. In this way, no water, otherthan an initial fill of the receptacle 136, is required to process thewaste. Moisture may also be collected, for reuse or to remove it fromthe processing module 44, by allowing it to condense on surfaces ofprocessing module 44 from where it drips or runs down surfaces to theforming chamber drain 100.

[0068] In the embodiment illustrated in FIG. 6, since the solid is drierthan the raw organic waste, and both liquid and gaseous forms of waterare at least partially recaptured, the processing module 44 may producean excess of water such that the receptacle 136 only needs to be filledon initial start up of the apparatus 30. However, the water in thereceptacle 136 contains organic matter. The concentration of the organicmatter is reduced by the recycled water from the moisture liquefyingdevice 132 and so does not tend to become excessive for use inprocessing organic waste. However, the water in receptacle 136 does notprovide an entirely clean source of water for rinsing the receivingmodule 32. For rinsing, switch 148 may be operated to connect water pump76 with a household water inlet 150 or to another reservoir dedicated toholding rinse water. Alternately, a water treatment device such as aclarifier or filter, may be added to the receptacle or in line withwater supply line 146 to treat the water in receptacle 136 to make itsuitable for rinsing. Further alternately, clean water reclaimed fromvapor produced while drying may be provided first to a reservoir forrinsing water and, if and when that reservoir is filled, to drain or toreservoir 136 for process water. In that way, clean rinsing water maystill be obtained without requiring a hook-up to a household watersupply. The receptacle 136 may also be configured or used to decant thewater entering it, with only an upper portion lean in solids re-used aswater and a lower portion rich in solids either sent to drain orreturned to the forming chamber 92, for example by flowing it onto asolid that is drying in the forming chamber 92. Whichever line supplieswater for rinsing may also be fitted with a heater or chemical injectorif a heater or disinfecting rinse is desired.

[0069] After the solid is dry and heating elements 102 are turned of,plungers 118 lift the solid upwards and move it sideways or rotate it sothat it drops to a receiving platform 110. Alternately, heating elements102 may be configured to not protrude into the solid or to beretractable and plungers 118 configured to slide the solid sideways offof the screen floor 96 through a hinged side panel in forming chamber92. Further alternately, forming chamber 92 may be configured so thatthe user can slide it out on a track to remove the solid. The systemcontroller 50 indicates that the solid is complete and the user may opena service door 112 or pull out the forming chamber 92. Forming chamber92 may also be made to slide out of the processing module 44automatically when the solid is complete. The user may then take thesolid away or store it in a pull out drawer 114 at the base of theapparatus 30. If desired, output can be produced that is sufficientlydry to be stored for two or three weeks or a month before it is thrownout, recycled, composted or used for another purpose.

[0070] The apparatus 30 may also be adapted for other configurations.For example, rather than standing in a fixed position, apparatus 30 maybe made partially mobile through the use of 360 degree free-roamingcasters 156 or other mobility devices such as wheels. Apparatus 30 mayalso be converted into a countertop unit by removing or relocating partsof the apparatus 30 below countertop base 152 shown in FIG. 6. To make acountertop apparatus 30 more compact and less tall, the receivingplatform 110 is replaced by a smaller volume pull out tray 154 whichalso, in use, provides limited storage of produced outcomes. In bothfree-roaming and countertop versions of apparatus 30, the use ofelements described above to recycle water may be sued to avoid the needfor any hook-ups to household water supplies or drains although the useris then required to fill and enter one or more reservoirs. Alternately,releasable water inlet and drain connections may be used. For example aninlet line may have a spring-loaded connection to a fitting on a sinkaerator and a drain line may be run from the apparatus 30 to dischargeinto a sink. A combined connection, for example a sink mounted inlet anddrain connection as used for portable dishwashers, may also be used.Depending on relative elevations, a free-roaming apparatus 30 mayrequire a pump to discharge water to drain.

[0071] For a countertop apparatus 30, reducing size is generallydesirable and so many features of the apparatus 30 described above maybe removed. For example, water recycling features may be deleted to makethe apparatus 30 smaller even though water and drain hook-ups may berequired. The system controller 50 and the processes it controls may bemade simpler or less automated which may reduce the size of the systemcontroller 50 and also remove the need for some related elements, suchas sensors. A less automated apparatus 30 may, for example, require theuser to input binder into the receiving module 32 to avoid the need forbinder reservoir 108 and binder transfer elements. Requiring the user toadd water to the receiving module 32 and rinse or wash the receivingmodule 32 manually or in a dish washer may remove the need for a waterpump 76 and various fluid conduits, valves and connections. The apparentsize of a countertop apparatus 30 may also be reduced by re-locatingsome of the large components. For example, motor 74 may be inverted andrelocated to where reservoir 136 is shown in FIG. 6 to reduce the heightof the apparatus 30. Using a pull-out forming chamber 92 as the means toremove the outcome, as discussed above, also helps reduce the height ofthe apparatus as no separate pull out tray 154 or mechanism to move theoutcome to the pull out tray 154 are then required. As for an under sinkapparatus 30, components above line 48 in FIG. 6 may be deleted orre-located. In particular, for a countertop apparatus 30, requiring thereceiving module 32 to be placed through a gate 52 requires the user tolift the receiving module 32 to an awkward height. Instead, componentsabove line 48 may be removed at least as required to allow the receivingmodule 32 to be placed directly onto the mating components directlybelow line 48. A latch or other mechanism may then be added toreleasably secure the receiving module 32 in place and, as discussedabove, the latch or other mechanism may interact with or power othersensors or functions. Alternately, the gate 52 and its relatedcomponents may be retained bu the track 54 reduced in height, forexample to about one half of the height of the receiving module 32 suchthat in position C of FIG. 7, the receiving module 32 protrudes from theprocessing module 44. In an embodiment, an inverted motor 74 is locatedbehind where the receiving module 32 sits on the processing module 44, apull out forming chamber 92 is used, there are no components above line48 where the receiving module 32 sits on the processing module 44 and alatch is used to engage the receiving module 32 to the processing module44. In this embodiment, the bottom of the apparatus 30 is near thebottom of the forming tray 92 and the receiving module 32 only needs tobe lifted several cm from the countertop to engage it with theprocessing module 44.

[0072] A horizontally sliding door or track may also be used in place ofgate 52 for either a countertop or free-standing apparatus 30. Forexample, the apparatus 30 may have a drawer or track that pulls out fromthe apparatus and accepts the receiving module 32 from the front, for acountertop apparatus 30, or from above, for a free-standing or roamingapparatus 30. The receiving module 32 becomes connected to theprocessing module 44 when the drawer or track is slid back into theprocessing module 44. For a countertop apparatus 30, this allows theapparatus 30 to be located further back on a counter to interfere lesswith working space on the counter. For a freestanding or roamingapparatus 30, this frees up the space formerly occupied by the gate 52to function as a work surface.

[0073] Methods for Making Use of the Outcomes

[0074]FIG. 9 shows a basic option tree for making use of the outcomes.First, a household, business or other user of organic matter creates anoutcome or, more typically, a collection of outcomes. The user may thenchoose between using the outcome personally and transferring the outcometo an organization.

[0075] For personal use, the user keeps the outcome and uses it asdesired. For example, the user may compost the outcome by simply placingit on an ordinary compost pile and allowing it to break down anddecompose. The binders in solid outcomes will break down on a compostpile and leave a collection of pieces of organic matter. Theconfiguration of the solid may be chosen to help the solid break downfaster. For example, an outcome in the shape of a thin sheet or diskwith holes through it breaks down rapidly when exposed to the weather.Alternately, an outcome in the form of pieces may be selected for evenfaster decomposition. In either case, the organic matter decomposesquickly because it is already reduced to pieces and the user may chooseto place the outcome directly where the compost is desired, such as in agarden, without first allowing the outcome to decompose in a compostpile. However, since the outcomes are durable and substantiallyodor-free if kept dry, outcomes may be collected over a period of daysand transported to a composting area when convenient. The outcomes mayalso be used for other purposes such as a fuel, animal feed, mulch or asa temporary insulator.

[0076] Users that do not wish to use the outcome themselves may transferthe outcome to an organization such as a municipality or environmentalcompany. For example, the outcome can be left for pick up in the sameway as ordinary garbage is left for pickup. In this case, the userreceives no direct consideration or incentive from the organization, butmerely enjoys the reduced odors and density, dryness and otheradvantages of the outcome. Alternately, the user may leave the outcomesfor separate pick up by an organization that will put the outcomes touse, such as a municipality running a composting program. In this case,the user still receives no material consideration although there areindirect benefits to the user such as a cleaner environment and reduceduse of landfills. But since the qualities of the outcomes make them moreagreeable to collect, store and transport than raw organic waste, userswill not have compelling reasons not to participate in municipalcomposting programs. In particular, even business users or users inapartments or condominiums will be able to participate in compostingprograms without significant inconvenience.

[0077] Alternately, the organization may encourage the user to produceand leave the outcome for pick up by providing consideration to theuser. The consideration may be provided directly. For example, theorganization may pay the user, in money, credits or by other means, foreach quantity of outcome left for pick up either each time a pick up ismade, or periodically after recording the amount left for pick up over aperiod of time. Alternately, the consideration may be provided through aless direct incentive such as a program that reduces the user's overallcost of garbage pickup or allows the user a larger volume of garbagepick up. For example, the organization may only pick up ordinary garbagein bags that have a tag that the user must purchase from theorganization for a fee. Containers of outcome, however, are picked upfree of charge. Optionally, further incentive can be provided by theorganization giving the user a tag for each specified quantity ofoutcome that the user leaves for pick up. For another example, theorganization may charge an annual fee for garbage pickup. The amount ofthe fee is related to the maximum number of bags of mixed garbage thatthe organization will be obliged to pick up per collection period.However, output separated from other garbage and left for pick up in anidentifiable container, such as a clear bag or open bin, will be pickedup for free and not counted towards the permitted maximum number of bagsof mixed garbage. In yet another example, the organization increases thetime between collections, for example to two weeks or more, eitherunilaterally or with the user's agreement. The organization spends lessmoney on collection and passes at least a portion of that savings on tothe user. The user also has to take out the garbage less often. Butsince raw organic waste would become extremely unpleasant over longperiods of time between pick ups, the user will want to convert as muchorganic waste to outcomes as possible.

[0078] As a further alternative, the user may transport the outcomes toa depot. Accordingly, users that do not have a garbage pick up service,for example rural residents, may transport the outcomes to a transferstation or other depot. At the depot, the outcomes may simply beaccepted as regular garbage without consideration. The user receives nobenefit but that the outcome is easier to transport than raw organicwaste and does not leave offensive odors even in a passenger car.Alternately, the user may receive some consideration analogous to theconsideration discussed above, for example, a waiver of the depot'sordinary fee for disposing outcomes separated from regular garbage or areduced fee for disposing regular garbage for every specified quantityof outcome left at the depot.

[0079] Since the outcomes may be transported without offense, depots mayalso be set up to collect outcomes independent of or as a supplement tothe existing garbage or non-organic recycling programs in effect in anarea. In particular, while only a limited number of users are able toproduce outcomes, the organizations operating existing garbage andnon-organic recycling programs may not wish to provide a separate pickup for outcomes. Instead, depots are provided to accept outcomes fromthose users capable of producing outcomes. To the extent that theexisting garbage and non-organic recycling programs reward users, or aremade to reward users, for reducing the volume of garbage to be picked upor the frequency of pick up, users will benefit from converting organicwaste to outcomes and taking it to the depot. Accordingly, a program ofencouraging businesses or households to divert organic waste to outcomescan be initiated by providing depots to accept the outcomes andsimultaneously providing pick up for other garbage or recyclablesaccording to a program that benefits those that bring outcomes to thedepots. For example, pick up for other garbage can be made lessfrequent, the number of bags of ordinary garbage that will be picked upcan be limited, or the user may be charged, at least in part, per bag ofordinary garbage picked up.

[0080] Benefit can also be provided based on the amount of outcomebrought by a user to a depot. This benefit can be used as an additionalor alternate way to encouraging businesses or households to divertorganic waste to outcomes without providing door to door pick up ofoutcomes. This benefit can also be used as a way for a company whichwants to make further use of the outcomes but has no connection with theorganization that collects other garbage to secure outcomes.

[0081] The depot may provide a benefit to the users in many ways. Forexample, the depot may simply pay the user, for example in money, creditslips, garbage collection tags or by other means, for every specifiedquantity of outcomes brought to the depot. The quantity of outcomes maybe specified by various means such as weight, volume, number of standardbags or number of solid outcomes of a standard size. The depot may makethe payment immediately or record the payment to an account. The usermay withdraw from the account from time to time or the amount in theaccount may be linked to other accounts of the user, for example theuser's municipal tax bill may be reduced by the amount in the account.

[0082] The depot may be manually operated, automatic or have a mix ofautomatic and manual functions. For example, the depot may have anattendant that records, either on paper or in a database, the amount ofoutcomes brought to the depot and the personal or account information ofthe user. Optionally, personal or account information may be embedded ona magnetic strip card that is swiped through a reader or linked to anaccount number that the user punches in at the depot to avoid the needto manually record the information. The outcomes themselves may also belabeled, for example with a bar code label applied manually by the useror automatically by the outcome producing apparatus, so that personal oraccount information is recorded as each unit of outcomes is placed inthe depot.

[0083] Through a combination of such methods, the depot may be fullyautomated. For example, the depot may have a container with a scaleplatform at the bottom and an opening at the top. The user swipes amagnetic card that transfers the user's account information to the depotand causes the depot to disengage a magnetic lock on the opening. Theuser then inserts the outcomes through the opening. When all outcomesare inserted, the user pushes a button that causes the depot to take andrecord the weight of the outcomes. The depot then either dispensesconsideration on the spot, or records the weight of outcome to theuser's account. At about the same time, the depot slides the outcomesoff of the scale platform into a storage area and re-engages themagnetic lock. Periodically, the organization running the depot picks upthe stored outcomes for further use.

[0084] Another fully automated depot as adapted may be used to work witha standardized size and shape of solid outcome. The depot has a slotthat the outcomes can be slid into. The slot contains a bar code readerthat scans the outcomes as they slide by. The bar codes give the depotthe user's account information so that the number of solids inserted canbe recorded to the user's account. If the solids are not bar coded, thedepot simply counts the number of solids slid into the depot and forevery one or other specified number of solids, issues a receipt or tokenredeemable elsewhere, a coin, garbage tag or other form ofconsideration.

[0085] Through any of these or other methods, an organization collectslarge numbers of outcomes for further use. The output may be used, forexample, as input to a large scale composting operation, as animal feedor fuel, or it may be simply bagged for re-sale to individuals or otherorganizations.

[0086] It will be apparent to those skilled in the art that theinvention may also be practiced in embodiments different from thosedescribed above. In particular, but without limitation, the inventionhas been described primarily for use in managing household organicwaste, but may be adapted for use in other applications, such ascommercial food processing or restaurant waste. Many other additions,deletions or modifications may be made to the embodiments describedabove without departing from the spirit and scope of the invention.

I claim:
 1. An outcome from a waste processing process or apparatuscomprising a collection of pieces of organic matter wherein the piecesare dry enough to substantially reduce odors produced by microbialgrowth.
 2. The outcome of claim 1 wherein the pieces have no dimensionlonger than about 2 cm.
 3. The outcome of claim 1 wherein the pieces aredry enough to be generally free of odors from microbial activity for aperiod of at least 3 days when stored indoors.
 4. The outcome of claim 1wherein the pieces are dry enough to be generally odorless for a monthor more when stored indoors.
 5. A solid having a substantially fixedshape and made of a collection of pieces according to claim
 1. 6. Thesolid of claim 5 wherein the pieces are bound together with abiodegradable binder.
 7. The solid of claim 5 wherein the pieces arebound together with a compostable binder.
 8. The solid of claim 5wherein the pieces are bound together with a carbohydrate binder.
 9. Thesolid of claim 5 wherein the pieces are closely packed or compactedtogether.
 10. The use of the outcome or solid of claim 1 as an interimform of organic matter created and existing after the organic matter isdeemed to be waste by a person, household or business.
 11. The use ofthe outcome or solid of claim 10 to facilitate the storage, transfer orexchange of the organic matter before it is discarded or used foranother purpose.
 12. A process for producing dried pieces of organicwaste comprising the steps of, reducing raw organic waste to pieces;and, drying the raw organic waste, wherein the organic waste may bedried before or after it is reduced; and, the organic waste is dried toa moisture content at which it is generally free of odors caused bymicrobial activity.
 13. A process for producing a solid, comprising thesteps of reducing raw organic waste to pieces; producing a mixture ofthe pieces, water and a biodegradable binder; forming the mixture into ashape; and, drying the shaped mixture.
 14. The process of claim 13further comprising the step of heating the shaped mixture.
 15. Theprocess of claim 13 further comprising removing liquid water from themixture.
 16. The process of claim 13 further comprising capturing watervapor emitted while drying the shaped mixture.
 17. The process of claim16 further comprising converting the captured water vapor to liquidwater.
 18. The process of claim 15 wherein the liquid water is re-usedin a subsequent process for producing a solid.
 19. The process of claim13 wherein the water or biodegradable binder in the mixture is obtainedfrom the raw organic waste.
 20. The process of claim 13 wherein thebinder is a carbohydrate.
 21. The process of claim 14 wherein the binderis activated by the heating.
 22. An apparatus comprising elementsadapted to perform the steps of claim
 13. 23. An apparatus for receivingand processing organic waste comprising, (a) a processing module adaptedto perform one or more of the steps of claim 13; and, (b) a receivingmodule adapted to receive organic waste and adapted to be connected toor released from the processing module, wherein when the receivingmodule is connected to the processing model, the organic waste may betransferred to the processing module and one or both modules may beoperated to perform the steps of claim
 13. 24. The apparatus of claim 23wherein the receiving module is portable.
 25. The apparatus of claim 23wherein the processing module is stationary.
 26. The apparatus of claim23 wherein the processing module is stationary while processing.
 27. Theapparatus of claim 23 wherein the processing module is located below asink or counter and the receiving module and processing module interfacethrough a hole in the sink or counter.
 28. The apparatus of claim 23wherein the receiving module is an under sink garbage disposer.
 29. Anapparatus for processing organic waste comprising, (a) a receiving areaor module having, (i) a first opening for admitting organic matter intothe receiving area; (ii) one or more sides defining a plenum incommunication with the opening for receiving and temporarily storingorganic matter; (iii) a reducing implement for reducing organic matterto pieces; and, (iv) a second opening for discharging reduced organicmatter from the plenum; and, (b) a processing area or module having, (i)a first opening in communication with the second opening of thereceiving module for receiving pieces of organic matter from thereceiving area; and, (ii) a form for supporting the organic matter whileit dries into a solid; and, (iii) a second opening for removing thesolid from the processing area.
 30. The apparatus of claim 29 whereinthe receiving area has a lid for closing the first opening.
 31. Theapparatus of claim 30 wherein the receiving area further comprises aclosure for the second opening and the lid and closure, when bothclosed, reduce the emission of odors from the plenum.
 32. The apparatusof claim 29 wherein the receiving area further comprises a screen withinthe plenum and the second outlet of the receiving area is locatedoutside of the screen such that organic waste may not pass to theprocessing area until it is less than the size of the openings of thescreen.
 33. The apparatus of claim 29 wherein the receiving area furthercomprises an inlet to add water to the plenum.
 34. The apparatus ofclaim 29 further comprising a vent for removing water vapor.
 35. Theapparatus of claim 29 further comprising a collector for collectingwater vapor.
 36. The apparatus of claim 35 further providing a waterextractor for extracting liquid water from the collected water vapor.37. The apparatus of claims 29 further comprising a receptacle forliquid water.
 38. The apparatus of claim 37 further comprising a passagefor liquid water to pass from the receptacle to the receiving area. 39.The apparatus of claims 37 wherein the receptacle receives liquid watercollected from extracted water vapor.
 40. The apparatus of claim 29further comprising an injector for introducing a binder to the organicmatter.
 41. The apparatus of claim 29 further comprising a heater forheating the shaped organic matter.
 42. The apparatus of claim 29 whereinthe receiving area is removable and replaceable from the processingarea.
 43. The apparatus of claim 42 wherein the communication betweenthe second opening of the receiving area and the first opening of theprocessing area is broken when the receiving area is removed and re-madewhen the receiving area is replaced.
 44. An apparatus for processingorganic waste comprising, (a) a plenum for receiving organic matter; (b)a first opening for admitting organic matter into the plenum; (c) areducing implement for reducing organic matter to pieces; (d) apassageway for transferring reduced organic matter from the plenum to aform for supporting the discharged organic matter; and, (e) a secondopening for removing the solid from the processing area.
 45. Theapparatus of claim 44 wherein the plenum has a lid for closing the firstopening.
 46. The apparatus of claim 44 further comprising a screenwithin the plenum and wherein the passageway is located between theoutside of the screen and the plenum, whereby organic waste does notenter the passageway until it has been reduced to less than the size ofthe openings of the screen.
 47. The apparatus of claim 44 furthercomprising an inlet to add water to the plenum.
 48. The apparatus ofclaim 44 further comprising a vent for removing water vapor.
 49. Theapparatus of claim 44 further comprising a collector for collectingwater vapor.
 50. The apparatus of claim 49 further providing a waterextractor for extracting liquid water from the collected water vapor.51. The apparatus of claims 44 further comprising a receptacle forliquid water.
 52. The apparatus of claim 51 further comprising a passagefor liquid water to pass from the receptacle to the plenum.
 53. Theapparatus of claims 51 wherein the receptacle receives liquid watercollected from extracted water vapor.
 54. The apparatus of claim 44further comprising an injector for introducing a binder to the organicmatter.
 55. The apparatus of claim 44 further comprising a heater forheating the shaped organic matter.
 56. A process for processing wastecomprising the steps of, producing a collection or solid of claim 1;and, composting the collection or solid.
 57. A process for operating aprogram making use of organic matter comprising the steps of,encouraging persons to produce collections or solids of claim 1;collecting the collections or solids; and, making use of the collectedcollections or solids.
 58. The process of claim 57 wherein the personsare encouraged by giving them consideration in return for thecollections or solids.
 59. The process of claim 57 wherein the organicmatter is made use of by composting it.
 60. An outcome according toclaim 1 having a moisture content of 20% or less, the percentagecalculated based on the weight of water in the outcome divided by theweight of the outcome including the water in it.
 61. An outcomeaccording to claim 1 having a moisture content between 5% and 15%, thepercentage calculated based on the weight of water in the outcomedivided by the weight of the outcome including the water in it.